TUBE HEATER TROUBLESHOOTING GUIDE

Transcription

1 TUBE HEATE TOUESHOOTING GUIDE MODELS: HLV Series Tube Heaterer THESE HEATES MUST BE INSTALLED AND SEVICED B TAINED GAS INSTALLATION AND SEVICE PESONNEL ONL. EAD AND UNDESTAND ALL INSTUCTIONS THOOUGHL BEFOE ATTEMPTING TO INSTALL, OPEATE O SEVICE THE DETOIT ADIANT PODUCTS COMPAN HEATE. FAILUE TO COMPL ITH THESE ANINGS AND INSTUCTIONS, AND THOSE ON THE HEATE, COULD ESULT IN PESONAL INJU, DEATH, FIE, ASPHXIATION AND/O POPET DAMAGE. ETAIN THESE INSTUCTIONS FO FUTUE EFEENCE. CAUTION! Heater may be hot. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Note presence of flammable gas and electrical shock hazard. ANING! Extinguish open flame while servicing heaters. Test for gas leaks with soap and water solution only. ear safety glasses while servicing unit. FO OU SAFET! IF OU SMELL GAS: 1. Open windows. 2. Do not touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier. SHUTDON INSTUCTIONS! 1. Open electrical circuit. 2. otate heater s manual gas valve knob to OFF position. Approval Standards and Certifications Detroit adiant Products units comply with or are certified by the following Organizations or Standards: - American National Standards (ANSI Z83.6) - Occupational Safety and Health Act (OSHA) - American Gas Association (AGA) - International Approval Services (IAS) IMPOTANT: Any alteration of the system or of the factory-authorized components specified either in this manual or by Detroit adiant Products Company voids all certification and warranties. Detroit adiant Products Company Hoover oad arren Michigan (586) Fax: (586) website: engineering@detroitradiant.com

2 Tube Heater Vacuum System arnings Detroit adiant Products Company cannot anticipate every use which may be made of their heaters. Check with your local fire safety authority if you have questions about local regulations. This infrared heater is designed for use in industrial and commercial buildings such as warehouses, manufacturing plants, aircraft hangars, service garages, etc. Maintain all clearances to combustibles at all times! See page 5 for clearance to combustibles guidelines. ANING! This heater must be installed and serviced by trained gas installation and service personnel only. ead and understand these instructions thoroughly before attempting to install, operate or service this heater. Failure to comply could result in personal injury, asphyxiation, death, fire, and/or property damage. etain these instructions for future reference. ANING! T FO ESIDENTIAL USE! Do not use in the home, sleeping quarters, attached garages, etc. ANING! Do not operate heater with any part bypassed, with any part failed or in any scenario that may compromise safety. ANING! This is not an explosion-proof heater. here there is the possibility of exposure to flammable vapors, consult the local fire marshal, the fire insurance carrier and other authorities for approval of the proposed installation. IMPOTANT! Any alteration of the system or of factoryauthorized components specified in this manual or by Detroit adiant Products Company voids all certification and warranties. 2

3 Operation 4. OPEATION 4.1 Electrical equirements 1. The system operates on 120V, 60 Hz. 2. The system must be grounded in accordance with the National Electrical Code NFPA 70 latest edition. 3. The system must be installed in accordance with the typical wiring diagrams (see Figures 4-1 & 4-2). 4. Figure 4-3 illustrates the wiring of a PB series pump assembly. 5. All systems are two-stage heat systems and will be operated by a two-stage controller. 6. Check vacuum pump to ensure wiring is correct for proper fan wheel rotation. Check directional arrow on pump housing for proper wheel rotation. 7. The amperage draws for the individual HLV components are as follows. The circuit(s) must be sufficient to handle the starting current of the buner control boxes and the running amperage of the pump. HLV VACUUM PUMPS UNNING CICUIT (amp) NC PB PB PB-10A Burner Lighting Instructions 1. Purge main gas supply line. 2. otate burner s manual gas valve knob to the ON position. 3. Close electrical circuit. 4. If burner fails to light, turn off gas and wait five minutes before repeating the above procedure. 4.3 Burner Shutdown Instructions 1. Open electrical circuit. 2. otate burner s manual gas valve to the OFF position. 4.4 Theory of Operation Starting Circuit (Figures 4.1 and 4.2) There is constant line voltage sitting at both the vacuum pump and burner(s). hen the thermostat closes it sends power to relays at both the vacuum pump and burner(s). At the vacuum pump, the relay closes to allow a completed circuit across L1 and L2. At the burner control box negative air pressure generated by the vacuum pump will cause the normally open differential switch to close. A low voltage circuit is completed from the secondary side of the transformer through the relay and pressure switch to the control module. The hot surface igniter is now immediately powered. After the ignitor has been powered for 4-5 seconds, the control causes the gas valve to open and then initiates a 15 second ignition trial. HLV BUNE CONTOL BOX CICUIT (amp) STATING UNNING unning Circuit After ignition, the flame rod monitors the flame. As long as a flame is present, the valve is held open. If proof of flame is not established within 15 seconds, the unit will attempt ignition two more times and then lock out. If lockout occurs, the control can be reset by briefly interrupting the power source. If the flame is established for a period of time and then lost, the control acts to close the valve within one second, and a new trial sequence identical to that at start-up is initiated. 25

4 Tube Heater Vacuum System Internal iring for Burner Control Box PESSUE SITCH TEMINAL OCK INDICATO LIGHTS FLAME OD IGNITO BUNE A B C D G FC1 FC2 TITON 2465H IGNITION MODULE S1 L1 L2 S2 MV1 GND O O T'STAT TEMINAL ELA BOAD G / TANSFOME P M C M P C V HI HI L1 GAS VALVE ON OFF 120VAC L2 Figure 4-1 Block iring Diagram L1 120V-240V AC L2 120V ELA BOAD O PESSUE SITCH T-STAT TEMINAL TITON 2465H IGNITION MODULE LIGHT FLAME OD FC1 FC2 S1 L1 L2 S2 MV1 GND O IGNITO G LIGHT LIGHT HI M P C Figure 4-2 Ladder iring Diagram 26

5 Installation Internal iring for Pump & Panel Assembly FUSE G COM NC TANSFOME 120V/230V G L1 L2 G 120V/230V O G COIL NC O G COIL NC COM COM INPUT FO ZONE #1 Figure 4-3 INPUT FO ZONE #2 IF USED 27

6 VACUUM PUMP CONTOL BOX (MOUNTED TO PUMP) - IN - N 1 2 COMMON + Tube Heater Vacuum System System Field iring Zone 1 Burner(s) N 1 2 INPUT FO ZONE #1 INPUT FO ZONE #2 (IF USED) Zone 2 Burner(s) (if second heat zone is to be used) THIS SHOS ADDITIONAL IING FO SSTEMS THAT ILL OPEATE ON TO TEMPEATUE ZONES TE: DO T EXCEED THE TOTAL NUMBE OF BUNES ALLOED PE SSTEM AS STATED IN THE PUMP APPLICATION GUIDELINES N 1 2 N 1 2 N 1 2 N 1 2 N 1 2 N 1 2 TO-STAGE CONTOLLE OUT - STAGE 2 (HIGH FIE) OUT - STAGE 1 (LO FIE) EXTENAL TANSFOME 120 V L1 L2 A COMMON IE IS EQUIED FO THEMOSTATS THAT EQUIE CONSTANT POE N 1 2 TO-STAGE CONTOLLE OUT - STAGE 2 (HIGH FIE) OUT - STAGE 1 (LO FIE) IN EXTENAL TANSFOME V L1 COMMON L2 A COMMON IE IS EQUIED FO THEMOSTATS THAT EQUIE CONSTANT POE Figure

7 Operation 4.5 System Start-Up and Damper Setting 1. echeck installation of gas piping, electrical, etc. 2. Preset primary and secondary dampers to half open. 3. Unassisted outside combustion air ducts (if required) must be installed before start-up. 4. Fan assisted outside combustion air ducts (if used) must not be connected to control box upon initial start-up. 5. To set the dampers, the system must be run for 20 minutes in High Fire Mode. Check to make sure all lights on the burner control are on. 7. Using a manometer with an adequate range, measure the vacuum at the burner (Figure 4-5) farthest away from the vacuum pump. Adjust the primary damper at the pump until the manometer reaches the specified reading shown in the chart below. 8. If secondary dampers have been installed in the system, connect manometer to the designated burner and set secondary damper to the specified reading shown in the chart below. 9. All dampers must now be readjusted a second time in the same order. Lock the dampers in place. 6. All dampers in the system are initially set to half closed. If a burner does not light and stay lit, the damper for that burner will need to be adjusted to get the burner to light for the initial 20 miniute start-up. Burner Control Box Vacuum Port hen measuring box pressure, make certain burner box lid is tightened securely. Figure 4-5 Each system damper must be adjusted to obtain the following box pressure. The systems must be operating for a minimum of 20 minutes before adjusting the dampers to the following setpoints. BTU ating Box Pressure (inches.c.) 50,000-60, / , , / , , / , , /

8 Tube Heater Vacuum System 5. MAINTENANCE The HLV Series Vacuum System requires basic maintenance to keep it operating at peak performance. This system requires no filters to be replaced. 1. outinely inspect the vent intakes and vent exhausts for dirt and/or obstructions. If dirt becomes a problem, installation of outside air intake ducts for combustion are recommended. 3. Annually inspect the exhauster system for abnormal noise. Consult factory for troubeshooting. 4. Periodically check the integrity of the combustion tube and heat exchangers. eplace if there are signs of structural failure. 2. Keep the aluminum reflectors clean using a light soap and water solution. Use a metal polish if reflectors are severely dirty. Maintenance of the reflectors can vary significantly depending on the environment. Date Maintenance Performed eplacement Components equied 30

9 Maintenance 5.1 Troubleshooting Chart General Trouble Shooting Chart SMPTOM POSSIE CAUSE COECTIVE ACTION Thermostat closed but nothing happens. 1. Blow n fuse. 1. eplace. 2. Defective thermostat. 2. eplace. 3. Defective vacuum pump relay. 3. eplace. 4. Loose or disconnected w ire. 4. epair as required. 5. Defective vacuum pump. 5. epair or replace. 1. Low vacuum pressure setting. 1. Adjust burner box to proper specified pressure. Thermostat closed. Vacuum pump operates. Vacuum indicating light off. 2. Loose or disconnected w iring. 2. eplair as needed. 3. Plugged or resrticted exhaust vent. 3. Clean. 4. Plugged vacuum pressure sw itch lines. 4. Clean or replace. 5. Defective circuit control. 5. eplace. Thermostat closed. Vacuum pump operates. Vacuum indicating light on. No glo-bar energization. 1. Defective glo-bar. 1. eplace. 2. Loose or disconnected w ire. 2. epair or replace. 3. Defective circuit control. 3. eplace. Thermostat closed. Ignition occurs. Burner cycles off and w ill not recycle. 1. System not grounded. 1. Connect electrical ground. 2. Defective circuit control. 2. eplace. 3. Vacuum pressure setting incorrect. 3. Adjust. 4. Low gas inlet pressure. 4. Provide required gas pressure. 5. estricted air inlet. 5. Clean Thermostat closed. Ignition occurs. Burner cycles off and w ill not recycle. 1. Low gas inlet 1. Provide required gas pressure. 2. Defective vacuum pressure sw itch. 2. eplace. 3. estricted air inlet. 3. Clean. 4. Vacuum pressure set incorrectly. 4. Adjust 31

10 Turn up thermostat. 32 Does the exhauster fan turn on? Does the igniter warm up and glow orange? HLV SEIES TOUESHOOTING FLOCHAT Find the source of the electrical problem. Is the incoming power at the exhauster panel assembly 120V/240V? Is there 120V/240V going to the burner control box? Find the source of the electrical problem. epair wiring or hose connections. Check for loose wiring or restrictions in hose connections to the pressure switch. Are they ok? The heater is equipped with a safety pressure switch. The switch is a normally open switch an located in the gas valve compartment. Temporarily place a jumper across the terminal of the switch. Be sure to reinstall the cover. Does the igniter glow orange? Find the source of the electrical problem between the thermostat and the panel assembly. Is being supplied to the exhauster panel assembly from the thermostat? Is being supplied from the thermostat to the terminal plug on the control box? Find the source of the electrical problem between the thermostat and the control box. Is the inlet or the outlet of the unit obstructed? Ie. ice, bird s nest, dirt, etc. Adjust dampers to achieve proper box pressure. Check the damper setting for the proper box pressures after the heater has run for 20 minutes. Are the settings correct? The exhauster may be faulty and may need replacing. Is there 120V/240V leaving the panel and going to the exhauster? Is the igniter physically damaged? eplace igniter. Check voltage at ingniter during the ignition sequence (usually 5 seconds after power to burner control box). Is it? emove obstruction. Is the resistance through the igniter 1 to 6 ohms? eplace Igniter. eplace faulty wiring. Check the fuse in the panel assembly. Is the fuse blown? eplace the fuse after checking that there is no probable cause such as difficulty in rotating the fan wheel. Is there coming off the secondary side of the transformer in the panel assembly? eplace transformer. There may be a faulty relay in the panel assembly. Consult factory. eplace the switch after verifying the following: * Baffle(s) is in the proper tube(s). * Heater, fan blower, squirrel cage, intake and exhaust are kept clean and free from dirt and obstructions. * There is not a negative pressure experienced at the area of intake (ie: attic space, high winds, very tight building). * The intake pipe exceeds the the maximum specifications. Tube Heater Vacuum System Installation, Operation, Maintenance and Parts Manual

11 After the igniter is warmed up, does the gas valve open? 33 Does the burner light? Does the burner stay on? Check voltage of internal transformer of burner box. Is there coming off the secondary side? Test for at valve during valve opening period (usually 5 seconds after power to the heater). Is there to valve? Check to make sure gas pressure is within minimum and maximum inputs, as indicated on AGA burner rating label. Is gas pressure OK? Is there a signal across L1 and ground at the circuit board? Press reset switch (if any) on transformer. If there is still no signal, replace bad transformer. Possibly, the circuit board and/or wiring harness is faulty. These should be replaced. Does the burner stay on for approx. 15 seconds and then shut off? eplace gas valve. Correct problem. Is the heater properly grounded? Is the polarity correct? If, correct problem. eplace bad circuit board. Make sure gas lines were purged of air. Check to make sure gas pressure is within minimum and maximum inputs, as indicated on AGA burner rating label. Is gas pressure OK? Correct problem. Is the gas cock in the ON position? Certain models have a separate glo-bar igniter and flame rod sensor located next to the glo-bar. Other models have a glo-bar igniter only, which acts as both an igniter and flame sensor. Does model in question have glo-bar ignitor only? Consult factory for proper parts. Tube Heater Vacuum System Installation, Operation, Maintenance and Parts Manual Does the heater stay on until call for heat ends? Troubleshooting ends. The following can cause the heater to shut down: * Improper grounding. * High winds. * Taking combustion air from the attic. * Dirty environment. * Baffle not located properly. * Fluctuating gas pressure. Does the burner come on and then turn off immediately (1 or 2 seconds)? Check to make sure that the pressure is within minimum and maximum inputs as indicated on AGA burner rating label. Is gas pressure OK? If, correct problem. Exhaust pressure switch may be faulty or there is a restriction in the exhaust. ith ammeter, check amperage at flame rod. Is it greater than 7 micro amps? Sensing rod is faulty or flame is weak. Check to make sure heater is operating at proper gas pressure as indicated on AGA burner rating label and then replace sensing rod if needed. Check to make sure flame sensor wire is OK and then replace circuit board.

12 NC COM Tube Heater Vacuum System Installation, Operation, Maintenance and Parts Manual Tube Heater Vacuum System 5.3 Parts List B 68A B B PS 56C V24 V V55A V56A V57A COIL 832 COM V FUSE TANSFOME 120V/230V NC NC COIL COM V Emitter Tube(s) Combustion Chamber B C 82 21B 26A 26B B 65I 26A 1216 V303 34

13 35 HLV SEIES PATS LISTING TP# ITEM TP# ITEM TP-1 CONTOL BOX COVE TP-303 IGHT END PANEL TP-5 FLANGE GASKET TP-304 CONTOL BOX TP-9 CONDUIT COUPLING TP-329 1/4" NEUTAL TEMINAL OCK TP-10 CONDUIT 4" X 1/2" TP-566 VENT LIMITING OIFICE TP-11 IGNITO BOX TP-801 CENTE PANEL TP-12 IGNITO BOX COVE TP-825 ISOLATION ELA BOAD TP-17 SIGHT GLASS KIT TP-828 OPEATIONAL INDICATO LIGHTS TP-19B 4" TUBE & EFLECTO HANGE / SPING CLIP TP-832 THEMOSTAT TEMINAL STIP TP-20C 120" EFLECTO TP E NAT. GAS VALVE - 1/2" TP-21B TUBE CLAMP TP E LP GAS VALVE - 1/2" TP-26A 10 FT. ADIANT TUBE STAIGHT TP '' BUNE TUBE ITH FLANGE TP-26B 10 FT. ADIANT TUBE STAIGHT (AL-TI) TP-1216 NC-7 EXHAUSTE PUMP TP-31B CONTOL BOX BACKET TP-1250 IGNITE TP-33B 1/2" GAS COCK TP-1251 TITON 2465H CICUIT BOAD TP-44 AI OIFICE /SCEEN - CONSULT FACTO TP-1254 IGNITE GASKET TP-56C 1/4" PESSUE TUBE - CONSULT FACTO TP-1289 EXHAUSTE MOUNTING TUBE FO NC-7 PUMP TP-65I 33" INTELOCKING BAFFLE TP-1502 HLV LEFT END PANEL TP-68A STAIN ELIEF BUSHING TP VA TANSFOME / FOOT MOUNTS TP-70 CONTOL BOX COVE GASKET (PE FOOT) TP-1527 SITCHING CONTOL ELA TP-76 UBBE GOMMET TP-1528 EXHAUSTE POST PUGE ELA TP-82 EFLECTO CENTE SUPPOT TP-1530 FUSE HOLDE TP-83 STAINLESS STEEL FLEX CONNECTO TP " X 8" ELECTICAL BOX TP-97 1/4" X 1/4" BASS INT./EXT. ATMOS. BAB FITTING TP-1566 EXHAUSTE CONTOL PANEL ASSEM w/ Electrical Components TP-105 EFLECTO END CAP TP-PS M. OPEN DIFFEENTIAL PESSUE SITCHES TP-106 EFLECTO CLIP (TP-61B) N.O. Differential Pressure Switch (50 TO 80MBTU/H) TP-122 GASKET FO AI OIFICE & AI COLLA (TP-61E) N.O. Differential Pressure Switch (90 TO 125MBTU/H) TP-200 BUNE (50 TO 100MBTU/H LP GAS) (TP-1261A) N.O. Differential Pressure Switch (140 TO 180MBTU/H) TP-201 BUNE (125 TO 225 MBTU/H NAT O LP GAS) (TP-1061A) N.O. Differential Pressure Switch (200 TO 225MBTU/H) TP-204 GAS OIFICE - CONSULT FACTO V-23 ISOLATION BOOT TP-208 "Z" MOUNTING BACKET V-24 OM GEA CLAMP TP-212 1/2" X 3" PIPE NIPPLE V-55A 4" ADAPTE TP-217 PESSUE BAB FITTING V-56A 5" ADAPTE TP-218 EXHAUST PESSUE TUBE (VINL) V-57A 6" ADAPTE TP-220 STAIN. STL. TUBE CLAMP (175 & 225 MBTU/H) V-301 PB-8 PUMP ONL TP-222 FLAME OD V-302 PB-9 PUMP ONL TP-222A FLAME OD IE V-303 PB-10A PUMP ONL TP-223 GAS MANIFOLD Parts List Tube Heater Vacuum System Installation, Operation, Maintenance and Parts Manual